Electric smelting furnace



Patented Sept. 22, 1925.-

UNITED sTA'rss.

PATENT OFFICE.

ixErnUNJs G. XLUGH, or' ANNIs'roN, ALABAMA, AssIGNon 'ro FEnnRALPHosPH'o-RUS COMPANY, or nmmGHAM, ALABAMA, A CORPORATION or ALABAMA.

EIMTBIC SHELT'LNG FURNACE.

Application led .Tune 10,

To 'all whom it'may whom.-

Be. it known thatv I, BETHUNE G-..KLUGH, a'citizen of the. United States of America, residing 'atAnnistom in the county of Calhoun and- State of Alabama, have invented certain new 'andnisef'ul Improvements in -Electric-'Smelting Furnaces, of which th following' is a specification.

.This invention relatesA to an electric furnace, especially adapted to the smeltinfr ofvnatural phosphates with the necessary uxing, reducingiand allo ing agents, and for the recovery of phosp lorie acid` and other valuable products by the cont-rolling 'and treatin(lr of -such' gases, fumes and other evolve materials, 'as emanate from such 'electric smelting operations.`

In order that the novelty, usefulness, and necessity to commercial operation of the various features of the furnace-described herein may be fully understood, I give below certain fundamental essentials which have l been determined in the actual operation of a number. of commercial size furnaces over long periods in the smelting of a mixture of natural phosphates, siliceous flux, carbon and iron in the production of ferrophosphorus, and in the recovery of phosphoric acid and other valuable products from the gases and fumes that emanated from said electric smelting operations,

Many electric furnaces have been designed especially for the smelting of natural phosphates, with siliceous flux and carbon reducing agents, but practically all of them have, either wholly or in part, serious fundamental defects when their characteristics are considered as applicable to the conditions governing the action of the above inaterials under suchjelectric smelting' operations Those characteristics which I regard as most essential are as follows:

1. The furnace design must admit of construction throughout froxn 'refractorymaterial, which will resist high temperatures, the chemical action of phosphoric acid, and the luxing action of slags involved in operations. and will also withstand expansion andcontraction incident to changes of telnpcrature, which occur in the commercial operation of such furnaces. The great difficulty of maintaining a joint of metal to refraetcry materials, when subjected to high 1920. Serial No. 387,807.

temperatures and chemically active gases and fumes, is well known 'to all practicedf in -the operation of furnaces treatmgsuch materials; hence it is essential for continuous and commercial operation, that the intenor of the furnace should preserve in its construction a continuity of refractory materials construction, and avoid metal, either Y and chemical action about the furnaces soon become unworkable, with resultant delays and losses which render the operation uncommercal.

3. The gases must have free passage from the furnace, as such, with no constriction or conducting them to the point for their subsequent treatment.

4. The electrodes should be in a Vertical position, because extended and\ exhaustive observation of lvsuch operations, as well a's authentic precedent of similarv or analogous operations, has demonstrated sitively that a furnace charge consisting o natural phosphates, siliceous flux and carbon in the proportions rcquired for the electric smelting of such' charge has such high electrical resistivity, that practically no current, (within the range of furnace operating voltages) can be passed through thev charge as such, and that the electric current for such electric smelting must be applied within the more conductive softened charges and molten slag in the bottom of the furnace. Since said slag, which term .is used hereafter to include both the slag proper and the softened charge. i. e., the charge in its intermediate state between solid and fluid condition, changes its elevation within the furnace by its for-- mation and tapping, and since the electrode4 must be in actual contact with such slag in order to maintain and control a uniform flow of current therein, it is obvious that 80 impeding, into the gas passage provided for such control can best be maintained with the electrodes at right angles to the horizontal plane formed'by the top surface of the slag, which means a vertical or substantially vertical position for the electrodes. (b) Furthermore, due to the fact that the electrodes, in the present state of the art respectin `their materials and construction, are rat er weak and fragile mechanically, and also due to the semiplastic nature of certain zones within the operating furnace for the smelting of materials lwithin described, it is impractical to manipulate, for operation, the electrodes in any substantially inclined or horizontal arrangement without electrode breakaee so excessive from the strains developed` therein that it would render the operation -uncommercial.

(c) The complexity.' of `the mechanical equipmentx and electrical connections necessary for operating electrodes which project into a furnace of commercial size in substantially vertically inclined or horizontal position,`is objectionable on account of thc high l cost of their maintenance and replacement in of exit of gases from within, nor are any materials oflcoi'istructioirfor such scaling available commercially within the present state of4 the'art o f electric smelting.

(e) Itis obvious, with electrodes inclined toward a common point within the furnace, that the points of the electrodes will come closer together as they are projected or ted down to follow the slag lcvel. This will malte impossible the desired control because as the electrodes are fed down to maintain their contact with the slag in controlling the current flow, the)1 will either join together and produce a dead short circuit, or will produce lier'y aicing by their close approach. j l

(f) lVhen opcii arcs occur within the furnace a dense fume is evolved composed of linie, silica, iron. and other constituents of the stock which clogs up all gas passages and re'iders the collection ofthe phosphorus compounds from the gases iml'n'aetical, :and

thc operation uucoinincrcial on account of interruptions. lVith vertically arranged electrodes the axes of their points will rc-` niain always cquidistant,A thus pil-rinitting control within such ranges as to prevent the formation of open arcs in thc furnace.

5. The stock within the furnace must be of a definite depth from its top surface to the bottoni of the furnace, in order to maintain definite zones vof chemical action, plastic state, and fusion. l-Vhen an electric furnace sinclting a charge as described is allowed to reduce the depth of its charge sufficiently t0 permit the stock therein to become abiiornially heated, the fume as described in the preceding paragraph is evolved with the results aforesaid. The chemistry or physics of this peculiar Vfume phenomena is' not that the depth of the charge within the furnace be automatically maintained constant and not subject to responsibility and judgment of workmen.

6. The top surface of the charge should remain quiescent, except for the slowly descending column of the stoel( as sinelted, and the furnace should also be charged so fui that no stock, upon entering the furnace will fall through the outgoing stream of gases. For, it is essential that no appreciable quantity of dust be entrained in the gases, since its removal is very difficult, especially if the gases be allowed to cool either en masse or upon the surface of cooling pipes or dust cliainbcis. l have found that dust is separated from gases at high temperature with Athe greatest difficulty, and that, when any poi-tion ofthe gases becomes cooled against an)- surface of its conducting apparatus, thc reaction between the phosphorus conipounds and the dust of any stock composition produces a highly adhesive and cementingr substance which quickly clogs up pipes and mains, the removal of which causes dclays `and expense, which may render the operation prohibitive in cost.-

'i'. The furnace should provide sufficient. space immediately above the charge and below the roof, to permit the` gases to pass out of the furnace with sufficiently low velocity to settle any incidental dust within the. furnace. lt is obvious that the exit of the gases at. high velocity through restricted parsagcs, will entrain dust. particles with the. disadvantages described in the preceding paragraph.

ts'. The furnace should be provided with suficiently flexible facilities for admitting and controlling the air to complete the conibustioii of the njas-cs within the furnace iinniediately above. the charge, or to partially burn the gases within the furnace innuellifi izo .60 and are continuous therefrom.

diately above the charge and partially within an auxiliary combustion chamber outside the furnace proper, or to conduct all the gases out of the furnace, andinto subsequent treating equipment, in the reduced state'.

The above flexibility is essential to meet the. varying conditions of raw materials, and changing specifications for the products,

which in turn must meet the varying comlncrcial conditions under which a commercialoperation may be conducted.

It is highly desirable that such vents or ports as are required to control the admission of air for such combustion control as above described, be constructed in the simplest ossible manner, and with a minimum `quantity of metallic connections and mechanical devices which when exposed to the 5l0A dust, heat and acid atmosphere will shortly become unworkable with incident delays and losses. Moreover, the air vents or ports should be of such size 'and so distributed that air may be admitted to, as well as distributedas unifrmly as possible over,l the area ofthe gas space in order that the combustion may be regular and continuous,

` thus avoiding spasmodic or explosive conditions. l

3 .9. Wherea combustion space is provided above the stock in the furnace it is essential vto protect the electrodes from exposure to the burning 'gases which would cause .their rapid' deterioration .and destruction, and the best and most practicable' means .to thus protect the electrode is to surround it with a column of stock which will continue upwardly through the electrpde opening .and

form the gas seal hereinbetore referred to.

4Q '-Based upon the foregoing fundamental requirements, I have designed and developed a `furnace which embodies all the requisite features. heretofore enumerated, :and which by actual operation has proven 4Q' its fulfillment of the same...

' vMy. invention in its preferred embodiment :is illustrated in the accompanyingr drawings -which form a part'of this specification, and

"in which I Fig. 1 is a vertical cross section of the furnace throughin electrode.

` ig. 2 is a Vlongitudinal vertical section .through the furnace. v Similar reference letters refer to similar parts throughout the drawings.

The bottom or hearth A may bc constructed of carbon, or other refractory material, The smelting zone walls B are mounted .directly upon the crucible .walls The thickness of these 'walls is continued upward a distance from the furnace bottom or hearth, that has been found in actual practice to be-thefbest operating. depth of the stock for 55 i''eatisfactory reacting zone. The side walls ffurnace.

C are in turn mounted upon and are continuous with the smelting zone walls B. The arch D is continuous with the lside walls C. The top ring or stock conduit E is built into the arch D, being 'a contiriuation of the 70 refractory construction of the entire furnace proper, which, being free from .any exposed metal parts, fulfills requirement 1. This top ring or stop conduit E, while built into the arch D forming the roof of thefurnace, 1s removable and replaceable from the exterior of the furnace without disturbing the integrity of the arch.

The opening F within the top ring E, provides a space forthe electrode G. The top .80 ring E, further Vprojects V,down into the 'furnace interior below the under surface arch D. This provides an annular space or clearance H between the surface of the electrode and the inner surface of the top ring E, ample for charging all the stock into. the

When the furnace `is filled with stock I, the annular space H will also be filled with the regular stock, Aand will thus,

due te its height of column filling this space,

.effectively and automatically seal the gases within the furnace from exit fthrough the charging or electrode o ning, thus fulfilling requirement 2 b sea g the gases, without the use of mec anical devices, packing rings or other com lex apparatus.

The/stock I wl have the apex of its natural angle of repose at the lowest point. y

of top ring E, which projects substantially into the furnace. This stock I will therefore form a conical or tapered sectionand not be projected directly against the side walls yor base of arch but will leave am le space or head room J for the gases, as cal ed for by requirements 5 and 7.

" The fresh stock as charged. into the will essentially, naturally and gradually descend' and flow over the to surface of the stock within the furnace, as t e smelting proceeds from below, thus the stock as charged into the furnace pro er will flow under the outgoing stream o gases which are passing through the combustion chamber, instead of dropping through them, thereby fulfilling requirement 6.

The electrode G is Suspended in vertical position thus fulfilling requirement 4.

The longitudinal vertical section through the electrodes of this furnace, shown in Fig. 2, shows how the gases will pass over the stock through the natural passage J through opening K into combustion chamber L and out "flue M Ato .subsequent treatment equipment. The ample exit passage provided in this construction fulfills. requirement 3. Reducedpressure within this .furnace may be 'maintained by a fan or a stack connected to gasexits, or by sufficiently large mains, conduits and subsequent treat-ing chambers designed for the free egress of gases from lao ' have their bottom contiguous with the wider top' surface of the smelting zone wall B which forms :t floor` for stock for regulating the size. of the port openings. This ventI provides for easy access from the outside of the furnace and for purposes of control, the. ports being closed with brit-k or with stock so that-the size ot' the opening is easily regulated. Thus essential requirement 8 is fulfilled.-

.The furnace. described with its combustion chamber above the stock and its arrangements-for the stoeh feed produces an entering and descending column of stock that surrounds'aml protects the electrode from e.\' posure to the lnirning gases, thus essential requirement 9 is fulfilled.

When any portion of the electrode is exposed to the gaf-es under the roof of-the furnace, the loss of elect rode b v the erosion and burning of the gases is so great as to render the cost of operation from the electrode. item alone, prohibitive. Further` the electrode so heated and decreased in section becomes more'resistant to the passage of the current, and thereby increases the current. consumption of the operation.

lt will wadil)v be seen by reference to the figules that without the, projection of the stock conduit through and below the arch at its apex the angle of repose. of thestoek would bring its-top surface so near the. nn-

'der surface of the arch that no appreciable gas space would be left and, by its natural flow, it might lie against the hase of arch and make the very simple port hole. con-v struction inipraettrahie.

The top ring or stock conduit projectingr within the furnace thus provides and fnnctions wit-hout metallic. or mechanical devices, as an electrode opening, :ostock charging opening, a stock column depth regulator, a means for maintaining the requisite gas .space and couihnstiou chamber between charge and roof, a gas seal, an eleet rode protector and a refraetor arch l\'e v ring. and it accomplishes all these ends without any mechanical complexity. \\'ith *the umin portions of the furnace constrncted-and proportioned so as' to integrate the above I'nnctionS. I attain an operative. etlieient and .automatic electric smelling furnace capable, of fnnct ioniug .as described for the. purposes set forth.

'hat I claim as new and desire. to sei-nre. bv Letters Patent. iszll. An enclosed electric. smclting furnace having a refraetollv -roof formed with n combined stoel: feed and eh-et rode openingr therein, a. vertically elongated stock feed conduit set into said opening and supported by said roof and adapted to depend into the furnace in position to impose the load of the entering stock therein upon the stock pile in the. furnace, said conduit having sutlicient length to canse the entering stock therein to seal the clearance about. th'e electrode passing therethrough. an electrode passing through said conduit and penetrating the `stock pile in the furnace, and an eduction Vin;r stock therein upon the stock pile in the furuace. said conduit hayine sufficient lengt h to cause theentering stoclfc therein to seal the clearance about the electrode'passin.;r therethrough, an electrode assing through said conduit and penetrating the stock pile in the furnace, and an cduction conduit for the evolved gases.

I?. ln an enclosed electric smeltin" furnace haring incorporated in its arched roof a stock feed conduit which depends into the furnace in spaced.relationship )vith the side walls-of the furnace, an electrode depending through said conduit, an eduction conduit for the evolved gases, said stock feed -conduit being disposed and adapted to maintain about the electrode an entering column of stoel; of sufficient depth to seal the elea rance about the electrode against the escape of s:iid gases-therethrough.

4. An enclosed electri smeltino furnace ha ving spaced refractory stock feed conduits spaced from each other and from the marginal walls of the furnace and projecting downwardly thereinto, each to the predeter .mined level of the apex of its respective- 'stock pile to be maintained within the furnace, which top level is substantially spaced below the furnace roof to provide an ample surroumling gas chamber above the stock piles, electrodes depending .through said conduits and penetrating the stock piles. and an ednction conduit'for the evolved gases leading directly from said -gus chamber.

los

llO

Au enclosed electric smelt-ing furnace space hetween the stock and the roof of the.

furnace and from which the gas is adapted to he cducted through said eductlon port.'

nace, a stock feeding conduit of refractory .material disposed and adapted to preserve an overhead combustion space between the stockand the roof of the furnace, a gas cduction conduit, and regulable means to control the volume and distribution of air admitted to said space. l

7. In an enclosed electric smelting furnace 'of the character described, a roof having a series of spaced openings therein, each adapted both for the passage of an elect-rode and the charging of stock around such electrode, a depending projecting lip surroundin each opening and terminating Sulliciently below the roof and so disposed as to insure ample head room forming a single chamber for gases between stock and roof, an eduction conduit for the evolved gases directly communicating with the entire gas s ace between the stock and roof, and a vertically adjustable electrodeadapted to pass centrally through each opening.

8. In an enclosed electric furnace of the character described having a gas outlet, a roof havin therein an electrode opening sufficiently l(larger in cross section than the electrode to permit of charging the stock therethrough, and means to elongate said opening by a replaceable internal refractory projection of the roof adapted to contain a column of stock that rests -on the stock in the furnace and that will seal the opening against escape of gases therethrough.

9. An enclosed electric furnace, provided with a'stock feed opening through the roof,

` a vertical'electrode suspended through said opening for conductin electric 'current into said furnace, a gas e uction conduit and a ring of refractory material concentric about the said opening and spaced sufficiently from the electrode to provide a stock charging space around said electrode, said ring o refractory material projecting within the furl nace sufficiently below the under surface of the arch so that the stock fed therethrough, in assuming its angle of repose in the furnace, will. leave ample space between said stock and the under surface of arch to permit free egress through said conduit. of 'gases emanating from said Stock While sealing the space around the electrode against the exit ,of said 'gases through said stock feed open ing, substantially as described.

10. An electric furnace, constructed continuously of refractory materials including a superimposed and enclosing arch; a suspended and keyed archring s in said arch and adaptedto project substantially below the under surface of said arch roof, the opening in said arch ring being adapted to form an electroderopening, n .stock chargin opening, a stock column height control, an

e stock being fed therethrough, a. seal of gases .within furnacethe. farnacc being further provided with multiplicity of air ports or vents and a gas outlet, und an internal shoulder at the bottom level of said ports adapted to hold furnace stock in position to regulate the area of opening for air admission through said ports.

1l. An electric furnace, constructed continuously of refractory materials including a superimposed and enclosing arch, an integral suspended and keyed arch ring which projects substantially below the under surface of said arch roof, the opening in said arch ring providing an electrode opening, a stock charging opening, a stock column height control, and, with the stock being fed therethrough, a seal of gases within the furnace, said furnace being further provided with a multiplicity of air ports so designed and proportioned as to be controllable as to area of opening for air admission by means of regular furnace stock, and a, combustion chamber external to and communicating with the upper part of said furnace an having air ports, said air ports providing for selective control of theA ont of complete combustion of gases eit er within theA furnace proper and above the charge or within chamber, orpartially within both, there being an eduction c qnduit for the rases. l2. An enclosed electric furnace having an air inlet and a gas outlet, a roof having a combined electrode passage and stock feed conduit, and a substantiall trode projecting through said conduit, -said parts being relatively arranged and adapted to utilize the stock within and entering the furnace to protect the electrode from .any exposure to the burning gases of the furnace.

13. In an enclosed electric furnace having a combustion space above the normal stock level therein, there being an air sup ly port ,for said space and an outlet there om for .the gases, an electrode traversing said combustion space, and means utilizing stock to protect the electrode from exposure to the burning gases in said combustion space.

14. In an electric smelting furnace, a refractory combination of roof, stock feed conduits and electrode passages, and electrodes ada'pted to contact with the sla bath' in the furnace, all disposed and a apted automatically responsive to the demands 0f the fusion zone to maintain a uniform depth of smelting stock above the slag bath.

l5. An enclosed electric furnace, havin in combination a roof formed entirely o refractory material and provided with .several stock feed conduits therein, saidstock feed conduits being each passage of an electrode t erethrough and sufficiently elongated Vto provide with the entering stock a seal against. the gases 1n said furnace, .and having their stock discharge vertical elec' rovided for the ends disposed in the furnace to produce a gas chamber between the discharged stock within the furnace and the said roof, said gas chamber being intercommunicative in all sections therein.

16. An enclosed electric furnace having a multiplicity of electrodes, each of said electrodes individually projecting through a separate refractory stock feed conduit set into the roof of said furnace and projecting sulicientb` below said roof to provide,

with the stock fed through said conduits, a continuous chamber between the said stock within the furnace and the roof of said furnace, said chamber being open and communicative about the entire space around said conduits and disposed and adapted for the free passage of the gases throughout said spae tu re.

BETHUNE G. KLUGH.

.In testimony whereof I affix rny signa- 20 

